Al 7075 Alaşımının İşlenmesinde Optimum Kesici Takım Geometrisinin Belirlenmesi: İstatiksel Bir Yaklaşım

Abstract

Bu çalışmada, havacılık ve otomotiv endüstrilerinde yüksek mukavemet/ağırlık oranı nedeniyle sıklıkla tercih edilen Al 7075 alaşımının frezelenmesinde takım geometrisi ve kesme parametrelerinin kesme kuvvetleri üzerindeki etkileri incelenmiştir. Deneyler için farklı boşluk (8°, 10°, 12°) ve talaş açısı (14°, 18°, 22°) kombinasyonlarına sahip 3 ağızlı karbür parmak frezeler özel olarak üretilmiştir. Taguchi L9 dizisine göre tasarlanan süreçte, kesme hızı (70, 85, 100 m/dk) da kontrol faktörü olarak kullanılmıştır. ANOVA sonuçları, kesme kuvvetini en çok %40 katkı oranıyla kesme hızının etkilediğini, ancak verilerin istatistiksel anlamlılık eşiğinin üzerinde kalıp birer eğilim göstergesi olduğunu belirtmiştir. Sinyal/Gürültü analizine göre optimum parametreler; 8° boşluk açısı, 18° talaş açısı ve 100 m/dk kesme hızı olarak belirlenmiştir. Ölçülen en düşük bileşke kesme kuvveti 469,72 N'dur. Sonuç olarak, düşük boşluk açısı ve yüksek kesme hızının birleşiminin kesme direncini düşürerek işleme verimliliğini artırdığı görülmüştür.

Keywords

• Al 7075
• Parmak Frezeleme
• Taguchi
• Kesme Kuvveti
• Takım Geometrisi
• Optimizasyon

Supporting Institution

Sakarya Uygulamalı Bilimler Üniversitesi Bilimsel Araştırma Projeleri (BAP) Komisyon Başkanlığına (Proje No: 130-2023)

Ethical Statement

Bu çalışma için, etik izin belgesine ihtiyaç yoktur.

Thanks

Bu çalışmanın maddi açıdan desteklenmesine olanak sağlayan, Sakarya Uygulamalı Bilimler Üniversitesi Bilimsel Araştırma Projeleri (BAP) Komisyon Başkanlığına (Proje No: 130-2023) teşekkür ederiz.

Determining the Optimum Cutting Tool Geometry for Machining Al 7075 Alloy: A Statistical Approach

Abstract

This study investigates the effects of tool geometry and cutting parameters on cutting forces in milling Al 7075 alloy, which is frequently preferred in the aerospace and automotive industries due to its high strength-to-weight ratio. Three-flute carbide end mills were specially manufactured with varying combinations of clearance angle (8°, 10°, 12°) and rake angle (14°, 18°, 22°). The experimental process used a Taguchi L9 orthogonal array with clearance angle, rake angle, and cutting speed (70, 85, 100 m/min) as control factors. Variance analysis (ANOVA) showed that cutting speed had the largest contribution ratio (40%) to cutting forces, with results serving as exploratory trend indicators. Signal-to-Noise (S/N) analysis identified 8° clearance angle, 18° rake angle, and 100 m/min cutting speed as the optimum combination for minimum cutting force. The lowest resultant cutting force measured was 469.72 N. The findings indicate that combining a small rake angle with a high cutting speed reduces cutting resistance and improves machining efficiency.

Keywords

• Al 7075
• End Milling
• Taguchi
• Cutting Force
• Tool Geometry
• Optimization

Supporting Institution

Chair of the Scientific Research Projects (BAP) Commission at Sakarya University of Applied Sciences (Project No: 130-2023)

Ethical Statement

No ethical approval is required for this study.

Thanks

We would like to express our gratitude to the Sakarya University of Applied Sciences Scientific Research Projects Coordination Unit (BAPK) for supporting project number 202-2024 in the execution of this study.

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